Brewing Facility Expansion
- EXPANDED CELLAR TO HOUSE ADDITIONAL FERMENTATION TANKS
- ADDED NEW PIPELINE AND FOUNDATION SUPPORTS
- REMODELED TO ACCOMMODATE INCREASED PRODUCTION FACILITIES, OFFICES, AND HOSPITALITY SUITE
- CREATED 3D MODELS OF EACH BUILDING ELEMENT AND DESIGN DELIVERABLE
VAA Leads Expansion of Summit Brewing Headquarters to Support Canning Operations and Increased Production
VAA was selected as a trusted partner to lead the expansion of Summit Brewing’s headquarters in response to growing consumer demand and the company’s entry into the canning market. VAA’s 3D modeling capabilities were used to allow viewing building elements and confirm design deliverables before construction began. The project was completed in three phases: expanding the cellar for additional fermentation tanks, installing pipelines and supports to connect brewing operations to a new canning area, and remodeling an adjacent building to accommodate canning production, office space, and a hospitality suite. VAA’s integrated approach ensured a seamless expansion aligned with Summit Brewing’s operational and growth goals.
Baking Facility Addition
- DESIGNED A 10,000 SF BAKERY FACILITY EXPANSION
- INCORPORATED A HYGIENICALLY ZONED PROCESS AREA WITH CONTROLLED ACCESS FROM GMP AREAS
- CONFIGURED A VERTICAL LAYOUT FOR PROCESS EQUIPMENT TO ADAPT TO THE ELONGATED BUILDING CONSTRAINTS
VAA assembled a multidisciplinary team to design a 10,000 SF bakery facility expansion featuring a baked bar line and additional office space.
VAA’s multidisciplinary teams provided a range of expertise, from preliminary engineering to construction documents and support. New food processing spaces had to be seamlessly connected to existing ones, and employee entrances needed to be rerouted around the expanded food processing space. VAA designed a hygienically zoned process area with controlled access from GMP areas, ensuring consistent quality and safety throughout the production process.
Freezer Expansion
- DESIGNED 40,000 SF FREEZER EXPANSION & REFRIGERATED DOCK
- MAXIMIZED FREEZER STORAGE IN RESTRICTED HEIGHT AREA
- NEGOTIATED SPECIALTY PERMITTING WITH DNR
Designed a 40,000 SF freezer expansion and refrigerated dock addition for a refrigerated ready-to-eat sandwich production facility.
VAA teams worked together closely to ensure that connections to existing food processing spaces were seamless, optimizing workflow efficiency, while maintaining strict food safety and temperature control standards.
VAA used 3D laser scanning to define the maximum available space for new spiral freezers and incorporated those constraints into equipment specifications for vendor quotes. Engineering analysis was performed to estimate freezer thermal and product load requirements across all stock keeping units, ensuring the design could handle varied product demands. Testing options for product freezing curves were identified, and a cost-benefit analysis performed to support the transition to a sustainable system.
Disciplines
- Civil Engineering
- General Arrangement
- Industrial Architecture
- Structural Engineering
- Electrical Engineering
Partners
- Corval Group
Food Manufacturing Facility
- EXPEDITED DESIGN & CONSTRUCTION PROCESSES
- REDUCED FABRICATION AND INSTALLATION TIME
- DESIGNED A CUSTOM HOT-WATER SKID
- MODELED AND ISO’D 3A DAIRY PROCESS PIPING
VAA designed a process addition within an existing facility that enabled the company to enter new markets.
VAA was hired to design a process addition to an existing facility for producing high-quality, food-grade pea protein. The multidisciplinary team handled everything from preliminary engineering to construction support. The project involved new hygienic process infrastructure, platforms, HVAC, dust collection, and plumbing, using a 3D facility scan for accurate integration. VAA also designed a CIP system for sanitation and collaborated on a mixproof valve skid to speed up fabrication. The coordinated approach optimized space and increased production capacity, enabling the client to enter new markets.